US20230354530A1 - Assembly of printed circuit board with overmolded epoxy to baseplate - Google Patents
Assembly of printed circuit board with overmolded epoxy to baseplate Download PDFInfo
- Publication number
- US20230354530A1 US20230354530A1 US17/661,652 US202217661652A US2023354530A1 US 20230354530 A1 US20230354530 A1 US 20230354530A1 US 202217661652 A US202217661652 A US 202217661652A US 2023354530 A1 US2023354530 A1 US 2023354530A1
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- US
- United States
- Prior art keywords
- pcb
- base plate
- encapsulation housing
- integrally formed
- layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000004593 Epoxy Substances 0.000 title claims abstract description 29
- 238000000034 method Methods 0.000 claims abstract description 27
- 238000000465 moulding Methods 0.000 claims abstract description 14
- 238000005538 encapsulation Methods 0.000 claims description 47
- 239000000463 material Substances 0.000 abstract description 18
- 239000000853 adhesive Substances 0.000 abstract description 7
- 230000001070 adhesive effect Effects 0.000 abstract description 7
- QHZSDTDMQZPUKC-UHFFFAOYSA-N 3,5-dichlorobiphenyl Chemical compound ClC1=CC(Cl)=CC(C=2C=CC=CC=2)=C1 QHZSDTDMQZPUKC-UHFFFAOYSA-N 0.000 description 29
- 230000005540 biological transmission Effects 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
Images
Classifications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K5/00—Casings, cabinets or drawers for electric apparatus
- H05K5/0026—Casings, cabinets or drawers for electric apparatus provided with connectors and printed circuit boards [PCB], e.g. automotive electronic control units
- H05K5/0082—Casings, cabinets or drawers for electric apparatus provided with connectors and printed circuit boards [PCB], e.g. automotive electronic control units specially adapted for transmission control units, e.g. gearbox controllers
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K5/00—Casings, cabinets or drawers for electric apparatus
- H05K5/0026—Casings, cabinets or drawers for electric apparatus provided with connectors and printed circuit boards [PCB], e.g. automotive electronic control units
- H05K5/0034—Casings, cabinets or drawers for electric apparatus provided with connectors and printed circuit boards [PCB], e.g. automotive electronic control units having an overmolded housing covering the PCB
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/22—Secondary treatment of printed circuits
- H05K3/28—Applying non-metallic protective coatings
- H05K3/284—Applying non-metallic protective coatings for encapsulating mounted components
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K5/00—Casings, cabinets or drawers for electric apparatus
- H05K5/02—Details
- H05K5/0217—Mechanical details of casings
Definitions
- the invention relates generally to a control unit having a connection structure for connecting components of the control unit to a base plate using an overmolding process.
- Control units are used in various technology areas, such as automotive, medical, or computing devices.
- One type of control unit such as a transmission control unit (TCU) is used to operate a transmission.
- TCUs typically include a printed circuit board (PCB) having various circuitry, and the PCB is mounted to a base plate. The PCB and base plate are then assembled into the cavity of a housing having various connectors which are in electrical communication with the PCB.
- the PCB is typically mounted to the baseplate using fasters or some type of adhesive, such as a thermally conductive adhesive.
- the present invention is a control unit having a connection structure for connecting components of the control unit to a base plate which is cost effective, and eliminates the need for separate fasteners.
- the control unit is a transmission control unit, but it is within the scope of the invention the control unit may be suitable for any application where a control unit is needed.
- control unit includes circuitry mounted to a PCB, and the PCB is mounted to a base plate.
- the circuitry is over molded with an epoxy material, such that the epoxy material flows from a top side of the PCB to underneath the base plate, such that the PCB is fixed to the base plate without the use of fasteners such as screws, or adhesive materials.
- the PCB is pre-assembled to the base plate, and this pre-assembly is over molded with an epoxy material to secure the PCB and the base plate together.
- the PCB and the base plate are aligned when placed in a tooling device by several half-punches, or alignment standoffs, formed as part of the base plate, or retractable pins in the tooling device. The tooling device clamps and holds the pre-assembly in place during the over molding process.
- the epoxy is used for mounting the PCB to the base plate, instead of using additional materials, such as an adhesive or fasteners.
- the PCB being mounted to the base plate using the over molding process results in no additional cost.
- the assembled PCB and base plate are over molded with an epoxy material.
- the epoxy material covers and protects the electronics mounted to the PCB. Compared to designs of current housings, the epoxy provides higher robustness and smaller packaging, while also securing the PCB to the base plate, eliminating the need for fasters or adhesive materials.
- the epoxy surrounds various parts of the PCB and the base plate, to connect the PCB and base plate together.
- the present invention is a control unit, including a base plate, a printed circuit board (PCB) connected to the base plate, and an encapsulation housing.
- the base plate and the PCB are connected together by the encapsulation housing.
- the encapsulation housing includes a first layer disposed on a side of the PCB, a second layer disposed on a side of the base plate, and the first layer and the second layer are connected together and connect the PCB to the base plate.
- control unit includes at least one flow aperture integrally formed as part of the base plate, and at least a portion of the encapsulation housing is disposed in the flow aperture, in between the first layer and the second layer.
- At least one recess is formed as part of the second layer of the encapsulation housing, and a portion of the base plate is adjacent the at least one recess.
- control unit includes a first plurality of assembly apertures integrally formed as part of the PCB, and a second plurality of assembly apertures integrally formed as part of the base plate.
- each of the first plurality of assembly apertures is aligned with a corresponding one of the second plurality of assembly apertures, and a portion of the encapsulation housing extends through each of the first plurality of assembly apertures and the second plurality of assembly apertures.
- control unit includes circuitry mounted to the PCB, and at least a portion of the circuitry is covered by the encapsulation housing.
- a connector shroud is mounted to the PCB in an area of the PCB unoccupied by the encapsulation housing. At least one circumferential flange is part of the connector shroud and is in contact with the PCB. The circumferential flange is disposed between a portion of the encapsulation housing and the PCB, securing the connector shroud to the PCB.
- control unit includes a cover integrally formed as part of the base plate, and a cavity integrally formed as part of the cover.
- a portion of the encapsulation housing is adjacent the cover, and the cover is adjacent the PCB in an area of the PCB unoccupied by the encapsulation housing.
- a circumferential lip is integrally formed as part of the base plate such that the circumferential lip circumscribes the cover, and a portion of the encapsulation housing is adjacent the circumferential lip.
- At least one groove is integrally formed as part of the encapsulation housing, and a portion of the base plate is disposed in the at least one groove, connecting the base plate and the encapsulation housing.
- FIG. 1 is a first perspective view of a control unit, according to embodiments of the present invention.
- FIG. 2 is a second perspective view of a control unit, according to embodiments of the present invention.
- FIG. 3 is an exploded view of several components which are part of a control unit, according to embodiments of the present invention.
- FIG. 4 is a partially exploded view of a control unit, according to embodiments of the present invention.
- FIG. 5 is a sectional view taken along lines 5 - 5 of FIG. 1 ;
- FIG. 6 is a sectional view taken along lines 6 - 6 of FIG. 1 ;
- FIG. 7 is a second sectional view taken along lines 6 - 6 of FIG. 1 ;
- FIG. 8 is an enlarged view of the circled portion of FIG. 5 .
- FIGS. 1 - 2 An embodiment of a control unit having a connection structure according to the present invention is shown in FIGS. 1 - 2 , generally at 10 .
- the control unit 10 includes a base plate 12 having a first side 12 a and a second side 12 b , a printed circuit board (PCB) 14 having a first side 14 a and a second side 14 b , and a connector shroud 16 .
- PCB printed circuit board
- first side 14 a of the PCB 14 Connected to the first side 14 a of the PCB 14 is various circuitry, shown generally at 18 .
- circuitry shown generally at 18 .
- pins There is also a plurality of pins, shown generally at 20 , which are connected to the first side 14 a of the PCB 14 and are part of the circuitry 18 .
- the pins 20 extend through the PCB 14 such that part of each of the pins 20 extends into a cavity, shown generally 22 , of a cover 24 , where the cover 24 is integrally formed as part of the base plate 12 .
- Integrally formed as part of the PCB 14 is a first plurality of assembly apertures 26
- integrally formed as part of the base plate 12 is a second plurality of assembly apertures 28 .
- four assembly apertures 28 formed as part of the base plate 12 but it is within the scope of the invention that more of less assembly apertures may be formed as part of the PCB 14 and the base plate 12 , respectively.
- Also integrally formed as part of the base plate 12 are two flow apertures 30 a , 30 b .
- a plurality of standoffs 12 c best seen in FIGS.
- first alignment standoff 12 d is formed as part of the first side 12 a of the base plate 12 .
- second alignment standoff 12 e is formed as part of the first side 12 a of the base plate 12 .
- the alignment standoffs 12 c , 12 d are greater in height than the standoffs 12 c , such that the alignment standoffs 12 c , 12 d protrude a greater distance away from the PCB 14 compared to the standoffs 12 c.
- the base plate 12 is made from aluminum, but it is within the scope of the invention that other materials may be used.
- the base plate 12 is formed using a stamping process, and during the stamping process, the base plate 12 is stamped from a metal blank, such that the standoffs 12 c and the alignment standoffs 12 d , 12 e are formed, as well as the cover 24 , and several connecting flanges 38 a , 38 b , 38 c .
- there is a circumferential groove 40 which is pressed into the second side 12 b of the base plate 12 , which results in the formation of a corresponding circumferential lip 42 on the first side 12 a of the base plate 12 .
- the connector shroud 16 is placed in contact with the first side 14 a of the PCB 14 , and the connector shroud 16 is properly aligned by alignment pins 32 which extend into the connector shroud 16 as the connector shroud 16 is placed in contact with the PCB 14 .
- the connector shroud 16 also includes a circumferential flange 16 a which is placed in contact with the first side 14 a of the PCB 14 during assembly.
- each alignment standoff 12 c , 12 d extends into a corresponding aperture (not shown) formed as part of the PCB 14 , and the second side 14 b of the PCB 14 is in contact with the standoffs 12 c and the circumferential lip 42 of the base plate 12 such that each of the first plurality of assembly apertures 26 is aligned with a corresponding one of the second plurality of assembly apertures 28 .
- the alignment standoffs 12 d , 12 e extending into corresponding apertures of the PCB 14 provide proper positioning of the base plate 12 and PCB 14 relative to one another during manufacturing.
- the desired positioning of the connector shroud 16 , the PCB 14 , and the base plate 12 forms a pre-assembly.
- the pre-assembly includes the connector shroud 16 being placed in contact with the first side 14 a of the PCB 14 , and the second side 14 b of the PCB 14 being placed in contact with the standoffs 12 c and the circumferential lip 42 as described above.
- the pre-assembly is placed into a tooling device, or a molding device, where several holding devices, such as clamps or the like, hold the pre-assembly in place while an epoxy material is injected into the tooling device during an over molding process.
- the epoxy material is injected into the tooling device to form an encapsulation housing 34 , which surrounds various parts of the base plate 12 , the PCB 14 , and the connector shroud 16 to function as a connection structure.
- the encapsulation housing 34 includes a first layer 34 a on the first side 14 a of the PCB 14 , and second layer 34 b on the second side 12 b of the base plate 12 .
- the epoxy material is injected into the tooling device such that at least a portion of the material flows through the first plurality of assembly apertures 26 and the second plurality of assembly apertures 28 , and portions of the epoxy material also flow through the flow apertures 30 a , 30 b .
- the shape of the layers 34 a , 34 b is determined by the shape of the tooling device.
- the first layer 34 a encapsulates most of the first side 14 a of the PCB 14 and also the circuitry 18 , with the exception of the area of the first side 14 a of the PCB 14 which the connector shroud 16 is attached to.
- several stanchions 60 are integrally formed as part of the encapsulation housing 34 . More specifically, the stanchions 60 are integrally formed with the first layer 34 a , the second layer 34 b , and the third layer 34 c . Each of the stanchions 60 extend through one of the first plurality of assembly apertures 26 and one of the second plurality of assembly apertures 28 .
- Part of the encapsulation housing 34 is also disposed between and in contact with the base plate 12 and the PCB 14 , with the exception of the areas of the PCB 14 which are in contact with the standoffs 12 c , the alignment standoffs 12 d , 12 e , and the circumferential lip 42 , and the area 54 of the PCB 14 which the circumferential lip 42 prevents the epoxy from contacting during the over molding process.
- This area 54 is adjacent the cavity 22 of the cover 24 .
- the second layer 34 b does not contact the entire second side 12 b of the base plate 12 .
- the second layer 34 b contacts the second side 12 b in the areas of the base plate 12 which are unoccupied by the cover 24 , and the second layer 34 b does not contact areas 36 of the base plate 12 which are adjacent the cover 24 .
- the encapsulation housing 34 also surrounds each peripheral wall 56 a , 56 b , 56 c , 56 d of the PCB 14 .
- the second layer 34 b has two parts which are located on the second side 12 b of the base plate 12 .
- the first part 42 a has a recess 44 a and the second part 42 b has a second recess 44 b , such that amount of epoxy used to create the second layer 34 b is minimized, reducing the overall weight of the control unit 10 , while still maintaining the proper structural integrity.
- the inclusion of the recesses 44 a , 44 b also results in a reduction in thickness of the parts 42 a , 42 b , which facilitates an even curing of the epoxy during the overmolding process.
- first groove 46 a which a first portion 48 a of the base plate 12 extends into
- second groove 46 b which a second portion 48 b of the base plate 12 extends into
- first shallow groove 50 a in which a third portion 48 c extends into
- second shallow groove 50 b in which a fourth portion 48 d extends into.
- Both of the shallow grooves 50 a , 50 b are adjacent different parts of the circumferential groove 40 .
- the circumferential flange 16 a is located between a portion 52 of the encapsulation housing 34 and the PCB 14 , securing the connector shroud 16 to the PCB 14 .
- control unit 10 described may be suitable for any type of application where a control unit is required, such as, but not limited to, an engine control unit, a transmission control unit, or the like.
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- Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Manufacturing & Machinery (AREA)
- Connector Housings Or Holding Contact Members (AREA)
- Casings For Electric Apparatus (AREA)
- Combinations Of Printed Boards (AREA)
Abstract
Description
- The invention relates generally to a control unit having a connection structure for connecting components of the control unit to a base plate using an overmolding process.
- Many applications use a control unit for controlling various components. Control units are used in various technology areas, such as automotive, medical, or computing devices. One type of control unit, such as a transmission control unit (TCU) is used to operate a transmission. TCUs typically include a printed circuit board (PCB) having various circuitry, and the PCB is mounted to a base plate. The PCB and base plate are then assembled into the cavity of a housing having various connectors which are in electrical communication with the PCB. The PCB is typically mounted to the baseplate using fasters or some type of adhesive, such as a thermally conductive adhesive.
- Current control unit designs have fasteners, such as screws, or adhesive to attach the PCB to the base plate, prior to the PCB and the base plate being assembled into the housing. This is costly and requires several manufacturing steps.
- Accordingly, there exists a need for a control unit which eliminates the need of separate fasteners used during assembly, and a separate housing.
- In an embodiment, the present invention is a control unit having a connection structure for connecting components of the control unit to a base plate which is cost effective, and eliminates the need for separate fasteners. In an embodiment, the control unit is a transmission control unit, but it is within the scope of the invention the control unit may be suitable for any application where a control unit is needed.
- In an embodiment, the control unit includes circuitry mounted to a PCB, and the PCB is mounted to a base plate. The circuitry is over molded with an epoxy material, such that the epoxy material flows from a top side of the PCB to underneath the base plate, such that the PCB is fixed to the base plate without the use of fasteners such as screws, or adhesive materials.
- In an embodiment, the PCB is pre-assembled to the base plate, and this pre-assembly is over molded with an epoxy material to secure the PCB and the base plate together. In an embodiment, the PCB and the base plate are aligned when placed in a tooling device by several half-punches, or alignment standoffs, formed as part of the base plate, or retractable pins in the tooling device. The tooling device clamps and holds the pre-assembly in place during the over molding process. In this embodiment, the epoxy is used for mounting the PCB to the base plate, instead of using additional materials, such as an adhesive or fasteners.
- In an embodiment, the PCB being mounted to the base plate using the over molding process results in no additional cost.
- In an embodiment, the assembled PCB and base plate are over molded with an epoxy material. The epoxy material covers and protects the electronics mounted to the PCB. Compared to designs of current housings, the epoxy provides higher robustness and smaller packaging, while also securing the PCB to the base plate, eliminating the need for fasters or adhesive materials.
- In an embodiment, there are four apertures in the PCB which are aligned with four apertures in the base plate when the PCB is placed in contact with the base plate to form the pre-assembly, where the epoxy flows through the apertures during the over mold process. The epoxy surrounds various parts of the PCB and the base plate, to connect the PCB and base plate together.
- In an embodiment, the present invention is a control unit, including a base plate, a printed circuit board (PCB) connected to the base plate, and an encapsulation housing. In an embodiment, the base plate and the PCB are connected together by the encapsulation housing.
- In an embodiment, the encapsulation housing includes a first layer disposed on a side of the PCB, a second layer disposed on a side of the base plate, and the first layer and the second layer are connected together and connect the PCB to the base plate.
- In an embodiment, the control unit includes at least one flow aperture integrally formed as part of the base plate, and at least a portion of the encapsulation housing is disposed in the flow aperture, in between the first layer and the second layer.
- In an embodiment, at least one recess is formed as part of the second layer of the encapsulation housing, and a portion of the base plate is adjacent the at least one recess.
- In an embodiment, the control unit includes a first plurality of assembly apertures integrally formed as part of the PCB, and a second plurality of assembly apertures integrally formed as part of the base plate. In an embodiment, each of the first plurality of assembly apertures is aligned with a corresponding one of the second plurality of assembly apertures, and a portion of the encapsulation housing extends through each of the first plurality of assembly apertures and the second plurality of assembly apertures.
- In an embodiment, the control unit includes circuitry mounted to the PCB, and at least a portion of the circuitry is covered by the encapsulation housing.
- In an embodiment, a connector shroud is mounted to the PCB in an area of the PCB unoccupied by the encapsulation housing. At least one circumferential flange is part of the connector shroud and is in contact with the PCB. The circumferential flange is disposed between a portion of the encapsulation housing and the PCB, securing the connector shroud to the PCB.
- In an embodiment, the control unit includes a cover integrally formed as part of the base plate, and a cavity integrally formed as part of the cover. A portion of the encapsulation housing is adjacent the cover, and the cover is adjacent the PCB in an area of the PCB unoccupied by the encapsulation housing.
- In an embodiment, a circumferential lip is integrally formed as part of the base plate such that the circumferential lip circumscribes the cover, and a portion of the encapsulation housing is adjacent the circumferential lip.
- In an embodiment, at least one groove is integrally formed as part of the encapsulation housing, and a portion of the base plate is disposed in the at least one groove, connecting the base plate and the encapsulation housing.
- Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
- The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
-
FIG. 1 is a first perspective view of a control unit, according to embodiments of the present invention; -
FIG. 2 is a second perspective view of a control unit, according to embodiments of the present invention; -
FIG. 3 is an exploded view of several components which are part of a control unit, according to embodiments of the present invention; -
FIG. 4 is a partially exploded view of a control unit, according to embodiments of the present invention; -
FIG. 5 is a sectional view taken along lines 5-5 ofFIG. 1 ; -
FIG. 6 is a sectional view taken along lines 6-6 ofFIG. 1 ; -
FIG. 7 is a second sectional view taken along lines 6-6 ofFIG. 1 ; and -
FIG. 8 is an enlarged view of the circled portion ofFIG. 5 . - The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
- An embodiment of a control unit having a connection structure according to the present invention is shown in
FIGS. 1-2 , generally at 10. Referring toFIGS. 3 and 5-8 , thecontrol unit 10 includes abase plate 12 having afirst side 12 a and asecond side 12 b, a printed circuit board (PCB) 14 having afirst side 14 a and asecond side 14 b, and aconnector shroud 16. - Connected to the
first side 14 a of thePCB 14 is various circuitry, shown generally at 18. There is also a plurality of pins, shown generally at 20, which are connected to thefirst side 14 a of thePCB 14 and are part of thecircuitry 18. Thepins 20 extend through thePCB 14 such that part of each of thepins 20 extends into a cavity, shown generally 22, of acover 24, where thecover 24 is integrally formed as part of thebase plate 12. - Integrally formed as part of the
PCB 14 is a first plurality ofassembly apertures 26, and integrally formed as part of thebase plate 12 is a second plurality ofassembly apertures 28. In this embodiment, there are a total of fourassembly apertures 26 formed as part of thePCB 14, and fourassembly apertures 28 formed as part of thebase plate 12, but it is within the scope of the invention that more of less assembly apertures may be formed as part of thePCB 14 and thebase plate 12, respectively. Also integrally formed as part of thebase plate 12 are twoflow apertures standoffs 12 c, best seen inFIGS. 3, 5, and 8 , is formed as part of thefirst side 12 a of thebase plate 12. Referring toFIG. 3 , there is also afirst alignment standoff 12 d and asecond alignment standoff 12 e which are formed as part of thefirst side 12 a of thebase plate 12. The alignment standoffs 12 c,12 d are greater in height than thestandoffs 12 c, such that the alignment standoffs 12 c,12 d protrude a greater distance away from thePCB 14 compared to thestandoffs 12 c. - In the present embodiment, the
base plate 12 is made from aluminum, but it is within the scope of the invention that other materials may be used. Thebase plate 12 is formed using a stamping process, and during the stamping process, thebase plate 12 is stamped from a metal blank, such that thestandoffs 12 c and the alignment standoffs 12 d,12 e are formed, as well as thecover 24, and several connectingflanges circumferential groove 40 which is pressed into thesecond side 12 b of thebase plate 12, which results in the formation of a correspondingcircumferential lip 42 on thefirst side 12 a of thebase plate 12. - Referring to the Figures generally, during assembly, the
connector shroud 16 is placed in contact with thefirst side 14 a of thePCB 14, and theconnector shroud 16 is properly aligned byalignment pins 32 which extend into theconnector shroud 16 as theconnector shroud 16 is placed in contact with thePCB 14. Theconnector shroud 16 also includes acircumferential flange 16 a which is placed in contact with thefirst side 14 a of thePCB 14 during assembly. ThePCB 14 is then positioned such that eachalignment standoff PCB 14, and thesecond side 14 b of thePCB 14 is in contact with thestandoffs 12 c and thecircumferential lip 42 of thebase plate 12 such that each of the first plurality ofassembly apertures 26 is aligned with a corresponding one of the second plurality ofassembly apertures 28. The alignment standoffs 12 d,12 e extending into corresponding apertures of thePCB 14 provide proper positioning of thebase plate 12 andPCB 14 relative to one another during manufacturing. - The desired positioning of the
connector shroud 16, thePCB 14, and thebase plate 12 forms a pre-assembly. The pre-assembly includes theconnector shroud 16 being placed in contact with thefirst side 14 a of thePCB 14, and thesecond side 14 b of thePCB 14 being placed in contact with thestandoffs 12 c and thecircumferential lip 42 as described above. The pre-assembly is placed into a tooling device, or a molding device, where several holding devices, such as clamps or the like, hold the pre-assembly in place while an epoxy material is injected into the tooling device during an over molding process. The epoxy material is injected into the tooling device to form anencapsulation housing 34, which surrounds various parts of thebase plate 12, thePCB 14, and theconnector shroud 16 to function as a connection structure. Theencapsulation housing 34 includes afirst layer 34 a on thefirst side 14 a of thePCB 14, andsecond layer 34 b on thesecond side 12 b of thebase plate 12. - During the over molding process, the epoxy material is injected into the tooling device such that at least a portion of the material flows through the first plurality of
assembly apertures 26 and the second plurality ofassembly apertures 28, and portions of the epoxy material also flow through theflow apertures layers areas 58 of the epoxy material which form part of theencapsulation housing 34 that extend through the first plurality ofassembly apertures 26 and the second plurality ofassembly apertures 28 is shown inFIGS. 6-7 . - Referring again to the Figures generally, in the embodiment shown, once the over molding process is complete, the
first layer 34 a encapsulates most of thefirst side 14 a of thePCB 14 and also thecircuitry 18, with the exception of the area of thefirst side 14 a of thePCB 14 which theconnector shroud 16 is attached to. Also, once the over molding process is complete, several stanchions 60 are integrally formed as part of theencapsulation housing 34. More specifically, the stanchions 60 are integrally formed with thefirst layer 34 a, thesecond layer 34 b, and the third layer 34 c. Each of the stanchions 60 extend through one of the first plurality ofassembly apertures 26 and one of the second plurality ofassembly apertures 28. Part of theencapsulation housing 34 is also disposed between and in contact with thebase plate 12 and thePCB 14, with the exception of the areas of thePCB 14 which are in contact with thestandoffs 12 c, the alignment standoffs 12 d,12 e, and thecircumferential lip 42, and thearea 54 of thePCB 14 which thecircumferential lip 42 prevents the epoxy from contacting during the over molding process. Thisarea 54 is adjacent thecavity 22 of thecover 24. Also, once the over molding process is complete, thesecond layer 34 b does not contact the entiresecond side 12 b of thebase plate 12. Thesecond layer 34 b contacts thesecond side 12 b in the areas of thebase plate 12 which are unoccupied by thecover 24, and thesecond layer 34 b does not contactareas 36 of thebase plate 12 which are adjacent thecover 24. Theencapsulation housing 34 also surrounds eachperipheral wall PCB 14. Once the over molding process is completed, thePCB 14 is protected from, and prevented from coming in contact with, fluids or gases. - The
second layer 34 b has two parts which are located on thesecond side 12 b of thebase plate 12. There is afirst part 42 a which is adjacent thecover 24, and asecond part 42 b which adjacent thecover 24 on the opposite side of thecover 24 as thefirst part 42 a. Thefirst part 42 a has arecess 44 a and thesecond part 42 b has asecond recess 44 b, such that amount of epoxy used to create thesecond layer 34 b is minimized, reducing the overall weight of thecontrol unit 10, while still maintaining the proper structural integrity. The inclusion of therecesses parts - Once the over molding process is complete, there are several grooves formed as part of the
encapsulation housing 34, and portions of thebase plate 12 are located in the grooves. Referring toFIGS. 5-7 , there is afirst groove 46 a which afirst portion 48 a of thebase plate 12 extends into, and asecond groove 46 b which asecond portion 48 b of thebase plate 12 extends into. Additionally, there is also a firstshallow groove 50 a in which athird portion 48 c extends into, and a secondshallow groove 50 b in which afourth portion 48 d extends into. Both of theshallow grooves circumferential groove 40. - Once the overmold process is complete, the
circumferential flange 16 a is located between a portion 52 of theencapsulation housing 34 and thePCB 14, securing theconnector shroud 16 to thePCB 14. - The
control unit 10 described may be suitable for any type of application where a control unit is required, such as, but not limited to, an engine control unit, a transmission control unit, or the like. - The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
Claims (18)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US17/661,652 US11910544B2 (en) | 2022-05-02 | 2022-05-02 | Assembly of printed circuit board with overmolded epoxy to baseplate |
CN202310483035.4A CN116997071A (en) | 2022-05-02 | 2023-04-28 | Mounting a printed circuit board to a substrate with an overmolded epoxy |
DE102023204030.1A DE102023204030A1 (en) | 2022-05-02 | 2023-05-02 | ASSEMBLY OF AN EPOXY OVERMOLDED CIRCUIT BOARD WITH A BASE PLATE |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US17/661,652 US11910544B2 (en) | 2022-05-02 | 2022-05-02 | Assembly of printed circuit board with overmolded epoxy to baseplate |
Publications (2)
Publication Number | Publication Date |
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US20230354530A1 true US20230354530A1 (en) | 2023-11-02 |
US11910544B2 US11910544B2 (en) | 2024-02-20 |
Family
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US17/661,652 Active US11910544B2 (en) | 2022-05-02 | 2022-05-02 | Assembly of printed circuit board with overmolded epoxy to baseplate |
Country Status (3)
Country | Link |
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US (1) | US11910544B2 (en) |
CN (1) | CN116997071A (en) |
DE (1) | DE102023204030A1 (en) |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6307749B1 (en) * | 2000-10-23 | 2001-10-23 | Delphi Technologies, Inc. | Overmolded electronic module with underfilled surface-mount components |
US20190080931A1 (en) * | 2016-03-04 | 2019-03-14 | Hitachi Automotive Systems, Ltd. | Resin-sealed vehicle-mounted control device |
US20200008292A1 (en) * | 2018-06-28 | 2020-01-02 | Alpine Electronics, Inc. | Electronic unit and method of making the same |
-
2022
- 2022-05-02 US US17/661,652 patent/US11910544B2/en active Active
-
2023
- 2023-04-28 CN CN202310483035.4A patent/CN116997071A/en active Pending
- 2023-05-02 DE DE102023204030.1A patent/DE102023204030A1/en active Pending
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6307749B1 (en) * | 2000-10-23 | 2001-10-23 | Delphi Technologies, Inc. | Overmolded electronic module with underfilled surface-mount components |
US20190080931A1 (en) * | 2016-03-04 | 2019-03-14 | Hitachi Automotive Systems, Ltd. | Resin-sealed vehicle-mounted control device |
US20200008292A1 (en) * | 2018-06-28 | 2020-01-02 | Alpine Electronics, Inc. | Electronic unit and method of making the same |
Also Published As
Publication number | Publication date |
---|---|
CN116997071A (en) | 2023-11-03 |
DE102023204030A1 (en) | 2023-11-02 |
US11910544B2 (en) | 2024-02-20 |
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